Plastic container having a carbon-treated internal surface

ABSTRACT

A blow molded container having barrier properties and including an upper wall portion having an opening, an intermediate sidewall portion positioned beneath the upper wall portion, and a base portion positioned beneath the intermediate sidewall portion to support the container. The container includes a molded outer layer having an inner surface and an outer surface formed from at least 40% of recycled plastic, and a carbon coating formed on the inner surface of the outer layer and adhered thereto and substantially coextensive with the outer layer, wherein said carbon coating has a thickness of less than about 10 microns.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-In-Part of copending U.S. patentapplication Ser. No. 09/370,642 for MULTI-LAYERED CONTAINER HAVINGCARBON-TREATED INTERNAL SURFACE AND METHOD FOR MAKING THE SAME, ByWilliam A. Slat, filed Aug. 6, 1999.

TECHNICAL FIELD

The present invention relates to plastic containers based on recycledplastic. More particularly, the present invention relates to blow moldedplastic containers based on recycled plastic, having barrier propertiesand having a carbon-coated internal surface.

BACKGROUND ART

It is highly desirable to provide plastic containers having barrierproperties, and it is also highly desirable to provide plasticcontainers using recycled plastic. However, recycled plastic generallydoes not have barrier properties and cannot be used in containers indirect contact with container contents. Therefore, despite the economicdesirability of using recycled plastic, the use of such material hasbeen difficult.

Conventionally, the use of recycled plastic in containers especiallythose holding contents for human consumption has been limited tomulti-layer plastic containers where the recycled plastic is an outerlayer which does not come into direct contact with the containercontents.

Multi-layer plastic containers are commonly used for packaging items ina wide range of fields, including food and beverage, medicine, healthand beauty, and home products. Plastic containers are known for beingeasily molded, cost competitive, lightweight, and generally suitable formany applications. Multi-layered containers provide the benefit of beingable to use different materials in each of the layers, wherein eachmaterial has a specific property adapted to perform a desired function.

Because plastic containers may permit low molecular gases, such asoxygen and carbon dioxide, to slowly permeate through their physicalconfigurations, the use of plastic containers sometimes proves to beless desirable when compared to containers formed from other lesspermeable materials, such as metal or glass. In most applications, theshelf life of the product contents is directly related to the package'sability to effectively address such molecular permeation. In the case ofcarbonated beverages, such as beer, oxygen in the atmosphere surroundingthe container can gradually permeate inwardly through the plastic wallsof the container to reach inside of the container and deteriorate thecontents. Likewise, carbon dioxide gas associated with the contents maypermeate outwardly through the plastic walls of the container untileventually being released on the outside, causing the carbonatedbeverage to lose some of its flavor and possibly become “flat”.

To address some to the foregoing concerns, plastic containermanufacturers have utilized various techniques to reduce or eliminatethe absorption and/or permeability of such gases. Some of the morecommon techniques include: increasing the thickness of all or portionsof the walls of the container; incorporating one or more barrier layersinto the wall structure; including oxygen-scavenging or reactingmaterials within the walls of the container; and applying variouscoatings to the internal and/or external surface of the container.However, a number of conventional barrier and/or scavenger materialswill not effectively curtail the permeation of both oxygen and carbondioxide over extended periods of time. Moreover, there are usually otherpractical concerns associated with most conventional techniques, mostcommonly, increased material costs and/or production inefficiencies.

In recent times, the use of plastics has become a significant socialissue. Recycling has become an increasingly important environmentalconcern and a number of governments and regulatory authorities continueto address the matter. In a number of jurisdictions, legislationpertaining to minimum recycled plastic content and the collection,return, and reuse of plastic containers has either been considered orhas already been enacted. For example, in the case of plastic containersused to hold consumable items, such as food items or beverages,regulations often require a certain content and minimum thickness of theinnermost layer that comes in contact with the contents. Conventionalprocesses, such as co- or multiple-injection molding, are often limitedas to the amount of recycled plastic that can be effectivelyincorporated into the structure of the container. Commonly, the amountof recycled content that can be effectively incorporated intoconventional co-injection molded containers that are suitable for foodcontents is less than 40% of the total weight of the container.

Therefore, a need exists in the industry and it is an object of thepresent invention to provide a plastic container having a high recycledcontent that is suitable for holding carbonated products, such ascarbonated beverages, and provides an acceptable level of performancewhen compared to commercial containers formed from alternativematerials. A further need exists for a method to produce such containersin high volume commercial rates using conventional equipment.

It is a still further object of the present invention and need toprovide a container based on recycled plastic which has barrierproperties and which minimizes or avoids the high cost of inconvenienceof conventional multi-layer plastic containers. It is a still furtherobjective to do this at a reasonable cost, in a commercially feasibleprocess, and with an effective product.

DISCLOSURE OF INVENTION

It has been found that the foregoing objects and advantages are readilyobtained in accordance with the present invention.

Recognizing the problems and concerns associated with conventionalmulti-layered plastic containers, especially those used to holdcarbonated beverages, a plastic container having enhanced gas barrierproperties and a high content of recycled plastic is advantageouslyprovided. A container constructed in accordance with the principles ofthe present invention provides several advantages over those previouslyavailable. Such advantages are generally realized through the use of thedesirable recycled plastic and a carbon coating on the internal surfaceof the recycled plastic. It is a significant advantage that thecontainer of the present invention has a significant amount of recycledcontent. Furthermore, the improved container can be produced usingconventional processing techniques and manufacturing equipment.

An important aspect of the present invention is the effective barrierproperties of the present container with the functional and commercialbenefits associated with having a container comprised a significantamount of recycled plastic content. Further, the ease in subsequentlyrecycling a container produced in accordance with the principles of thepresent invention make the practice of the invention extremelyadvantageous. Moreover, the present invention provides the additionaladvantage of permitting the manufacturer to controllably vary thematerial positioning and wall thickness at any given location along thevertical length of the inner and/or outer layers of the container.

In accordance with the principles of the present invention, a blowmolded multi-layer container is provided having an upper wall portion,an intermediate sidewall portion positioned beneath the upper wallportion, and a base portion positioned beneath the intermediate sidewallportion, the base portion being adapted to dependently or independentlysupport the container. The container includes a molded outer layerformed from recycled plastic and a carbon coating on the inner surfaceof the molded outer layer that is substantially coextensive with theinner layer. The recycled outer layer comprises at least 50% by weightof recycled plastic, but can comprise more than 75% by weight anddesirably more than 90% by weight, depending upon the needs of theapplication. In a preferred embodiment, the thickness of the outer layeris controllably adjusted along its vertical length. If desirable, theouter layer may also include additional barrier materials and/or oxygenscavenging/reacting materials incorporated therein.

Other and further advantages and novel features of the invention arereadily apparent from the following detailed description of the bestmode for carrying out the invention when taken in connection with theaccompanying drawings, wherein, by way of illustration and example,embodiments of the present invention are disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more readily understandable fromconsideration of the accompanying drawings, wherein:

FIG. 1 is an elevation view of a container in accordance with theprinciples of the present invention.

FIGS. 2, 3 and 4 are cross-sectional and enlarged views of various areasof the container wherein the relative thicknesses of the layers formingthe container are illustrated.

FIG. 5 is a partially broken away elevation view of one example of apreform.

FIG. 6 is a partially broken away elevation view of another example of apreform.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to the drawings in detail, wherein like reference numeralsand letters designate like elements, there is shown in FIG. 1 anelevational view of a container 100 constructed in accordance with theprinciples of the present invention. Container 100 typically includes anupper wall portion 112, including an opening 113; an intermediatesidewall portion 114 positioning beneath the upper wall portion 112; anda base portion 116 positioned beneath the intermediate sidewall portion114. The base portion 116 is adapted to support the container 100 eitherdependently, i.e., where another object such as a base cup (not shown)is used, or independently, i.e., where no other objects are needed tostand the container upright on a generally flat surface. In a preferredembodiment, the container 10 is supported by a freestanding base formedby a plurality of integrally formed feet 118, such as those illustratedin FIG. 1.

Referring to FIGS. 2-4, which represent enlarged detailed views of areas100A, 100B and 100C, respectively, of FIG. 1, the container 100 includesa molded outer layer 120, having a vertical length, an inner surface122, an outer surface 123 and a central vertical axis B. The innersurface 122 of the molded outer layer 120 is at least partially coatedwith a thin layer or film of carbon 124. While complete encapsulation ofthe inner layer 120 by the carbon layer 124 is preferred, it may not berequired for particular applications. It is preferred that the moldedouter layer 120 is substantially coextensive with the carbon layer 124and provide structural support for the container 100.

The molded outer layer 120 includes at least 50% of recycled plasticmaterial, desirably at least 75% of recycled plastic, and may include asmuch as 90% recycled plastic material. If desired, the molded outerlayer may be 100% recycled plastic material. Preferably, the moldedouter layer is formed from recycled polyethylene terephthalate (PET),but the present invention is not limited thereto and virtually anyrecycled plastic may be conveniently employed.

The molded outer layer 120 desirably comprised of a thermoplasticmaterial. The following resins as well as others may be convenientlyused as plastic materials for the outer layer 120: polyethylene resin,polypropylene resin, polystyrene resin, cycloolefine copolymer resin,polyethylene terephthalate resin, polyethylene naphthalate resin,ethylene-(vinyl alcohol) copolymer resin, poly-4-methylpentene-1 resin,poly(methyl methacrylate) resin, acrylonitrile resin, polyvinyl chlorideresin, polyvinylidene chloride resin, styrene-acrylo nitrile resin,acrylonitrile-butadien-styrene resin, polyamide resin, polyamideimideresin, polyacetal resin, polycarbonate resin, polybutylene terephthalateresin, ionomer resin, polysulfone resin, polytetra fluoroethylene resinand the like.

Desirably, the outer layer may be blended with other materials, asvirgin polyethylene terephthalate, polyethylene naphthalate (PEN),and/or blends of polyethylene terephthalate and polyethylenenaphthalate. However, other thermoplastic resins may also be blendedwith the recycled plastic.

It is particularly desirable to blend small amounts of barrier materialsand/or oxygen scavenging or reacting materials with the recycledplastic. For example, less than 5% by weight of saran, ethylene vinylalcohol copolymers (EVOH) and acrylonitrile copolymers, such as Barex.The term saran is used in its normal commercial sense to contemplatepolymers made for example by polymerizing vinylidene chloride and vinylchloride or methyl acrylate. Additional monomers may be included as iswell known. Vinylidene chloride polymers are often the most commonlyused, but other oxygen barrier materials are well known.Oxygen-scavenging materials can include materials marketed for such apurposes by several large oil companies and resin manufacturers. Aspecific example of such a material is marketed under the trade nameAMOSORB and is commercially available from the Amoco Corporation. Inaddition, the present invention can readily use ultra low intrinsicviscosity (IV) material, e.g., material having an IV of less than around0.60 or 0.55. These materials are frequently white or whitish in color.A significant advantage of the present invention is ability to processin-process scrap simply and efficiently, even with materials asaforesaid.

The inner surface 122 of the outer layer 120 is coated with a thin layerof carbon 124 which provides enhanced barrier properties to thecontainer 100. In a preferred embodiment, the carbon coating 124 iscomprised of a highly hydrogenated amorphous carbon that is doped withnitrogen. The thickness of the carbon coating 124 is less than about 10μm and the weight of the coating 124 is less than about {fraction(1/10,000)}th of the total weight of the container. An important featureof the present invention is that only about 3 mg of the carbon coating124 is needed to treat a 500 cc plastic container. Further, despite thenotable thinness of the carbon coating 124, the amount of barrierprotection afforded is quite significant and the protection frompermeation of oxygen and carbon dioxide is favorable when compared withthe protection found in metal cans and glass bottles. Thus, for example,the barrier provided in connection with the present invention againstoxygen permeation can be more than thirty times better than that of acontainer formed from untreated PET; the barrier provided against carbondioxide permeation can be more than seven times better than that of acontainer formed from untreated PET; and the barrier provided againstthe migration of total aldehydes can be more than six times better thanuntreated PET.

The molded outer layer 120 has a wall thickness, taken along itsvertical length, that is in the range of 6 to 23 mils (0.1524 mm to0.5842 mm). As illustrated in FIGS. 1-4, the thickness of the outerlayer can also be separately and independently varied along its verticallength. In this manner, different portions of the container 100 (takenperpendicular to the central vertical axis B) can have differentthicknesses, all by design. For instance, the thickness of the moldedouter layer 120 positioned at the upper portion 112 (such as shown inFIG. 2) can be much thicker than the intermediate sidewall portion 114(such as shown in FIG. 3). Likewise, the thickness of the outer layer120 at the base wall portion 116 (such as shown in FIG. 4) can bethicker than the thickness of the same layer in the intermediatesidewall portion 114 such as shown in FIG. 3). Because the molded outerlayer 120 is generally comprised of a less expensive plastic materialthat does not directly contact the contents of the container 100, a lessexpensive material can be used to form the bulk of the containerincluding a number of the structural integral components for thecontainer, such as the neck flange 126 and outer threads 128 shown inFIG. 1.

Similarly, the inner carbon coating can be readily varied so that thethickness thereof varies along the vertical length of the container.Desirably, however, for convenience a substantially uniform carboncoating is provided.

A significant advantage of the present invention is its ability toprovide significant barrier properties, incorporate a high content ofrecycled plastic material, and be advantageous to present day recycling.The outer layer 120 is comprised of plastic material and can be readilyrecycled. Unlike a number of other barrier materials often used inconnection with multi-layer containers, which can be difficult toseparate, the carbon coating 124 of the present invention has no impacton the recycling of the plastic materials of which the container 100 iscomprised.

The present invention includes the additional advantage of being able toprovide a container 100 with enhanced barrier properties that can beused for holding food products. Plastic containers having an innersurface treated with an amorphous carbon film have been approved forcontact with food products from the Technische National Onderzoek, thestandards organization accredited by the European Economic Community.The approval of the United States Food and Drug Administration (USFDA)is currently in process.

The container of the present invention may be formed by any of severalknown processing techniques which permit the manufacture of a singlelayer or multi-layer blow molded container. This represents aconsiderable advantage. In a preferred embodiment, the container 100 isformed via a blow molding operation involving a preform 130, such as theone generally depicted in FIG. 5. Although not a required feature, thepreform 130 may include a neck flange 132 (for handling purposes) andouter threads 134 (to secure a closure) that corresponds to the samefeatures shown in FIG. 1. After the blow molding of the container toform the final container 100 an embodiment of which is shown in FIG. 1,but some time before the filling operation, the inner surface 122 of thecontainer is carbon-treated as further discussed below.

In a first embodiment, a preform 130 which will become the container isproduced by extrusion molding a preform 130 with a preform body 136 anda preform inner surface 138. An extrusion process permits themanufacturer to readily vary the thickness of material being extrudedalong the length of the extrudate.

Variations in the thickness of the preform is desirable for severalreasons which include aesthetics, efficient material use and reducedcosts, and variable strength requirements.

The preform 130 is formed from at least 50% of recycled plastic materialwhich, as indicated hereinabove is a particular advantage of the presentinvention.

In a second embodiment, a preform 140 as shown in FIG. 6 is produced bythermoforming a thin sheet of plastic material and forming that sheetinto what will become the preform 140, or injection or compressionmolding the preform 140. Thus, preform 140 of FIG. 6 may include a neckflange 142 and outer threads 144, body portion 146 which will become thecontainer body portion and base portion 148 which will become thecontainer base portion.

The container can then be blown using conventional blow moldingoperations. Because the preform will be stretched and “thinned-out”during the subsequent blow molding process, the thickness of thepreform, at portions corresponding to like portions of the blowncontainer, will inherently be somewhat thicker. In fact, the thicknessof the various portions of the preform are typically designed to takeinto account the amount of stretch and hoop expansion necessary to formthe thickness profile desired in the final container 100.

After the preform has been formed into an intermediate container by blowmolding, a carbon coating is formed on at least a portion of the innersurface 122 of the container 120 and preferably on the entire innersurface. The carbon coating 124 does not have to be immediately appliedto the container, however, it is generally more efficient to apply thecarbon coating promptly after the intermediate container has been blownand is within an appropriate temperature profile.

In a preferred embodiment, the blown intermediate containers are removedfrom a conventional high-speed rotary blow-molding machine andsubsequently transferred, directly or indirectly (i.e., via intermediatehandling steps), to an apparatus for applying a carbon coating 124 tothe intermediate containers. In high-speed production applications, thecarboncoating apparatus will typically also be of the rotary type. Anexample of such an apparatus that can be used to apply the carboncoating to the inner surface of the intermediate containers is availablefrom Sidel of Le Havre, France and is commercially marketed under the“ACTIS” trade name.

A method for carbon-coating the intermediate containers is nextdescribed in further detail. In accordance with a preferred method forcarbon coating the inner surface of the intermediate container, aconventional carbon-coating or carbon-treating apparatus having rotarykinematics and a central vertical axis is provided. The carbon-coatingapparatus generally rotates about its central vertical axis in a firstrotational direction, e.g. counterclockwise, at a fairly high rotationalspeed. A blow-molding machine, or other rotary container transfermechanism, located generally in close proximity to the carbon-coatingapparatus functions as the source of intermediate containers forsubsequent carbon-coating treatment. To facilitate the transfer, therotary container transfer mechanism rotates in a direction opposed tothe rotational direction of the carbon-coating apparatus, e.g.,clockwise, and the intermediate containers are mechanically shifted fromthe container transfer mechanism to the carboncoating apparatus.Although not required for the practice of the present invention, theintermediate container preferably includes a neck flange or otherphysical means for at least partially supporting the intermediatecontainer during the mechanical transfer process.

As the intermediate containers are transferred from the transfermechanism to the carbon-coating apparatus, they are preferably held inan upright orientation with the opening thereof generally facingupwardly. If desired, a vacuum can also be generated and used to supportor partially support the intermediate container. During the transferprocess, the individual containers are received by a receiving mechanismwhich is part of the carbon-coating apparatus. The receiving mechanismrevolves around the central axis of the carbon-coating apparatus, graspsor secures the container, and seals the opening of the intermediatecontainer, much like a lid. When properly positioned over and abuttingthe opening, the receiving mechanism produces a tight to “airtight” sealover the intermediate container.

The receiving mechanism includes at least two apertures positioned abovethe opening of the intermediate container that are used for theintroduction and removal of gases from the inside of the intermediatecontainer. A first aperture in the receiving mechanism is incommunication with a vacuum source, such as a vacuum pump. After thereceiving mechanism has securely sealed the opening, the air within theintermediate container is discharged through the first aperture by meansof a vacuum. It is desirable that degree of vacuum falls within a rangeof about 10⁻² to 10⁻⁵ torr, so as to shorten the discharge time for avacuum and saves necessary energy therefor. With a lower degree ofvacuum of over 10⁻² torr, impurities in the container are muchincreased, on the other hand, with a higher degree of vacuum under 10⁻⁵torr, increased time and a large energy are needed to discharge the airin the intermediate container.

Once the air inside the intermediate container has been evacuated, theintermediate container is subsequently filled or “charged” with a rawgas that will be used in the formation of the carbon coating as shown inFIGS. 1-4. The flow rate of the raw gas is preferably within a rangefrom about 1 to 100 ml/min. Preferably, the diffusion of the raw gaswithin the intermediate container is enhanced by providing an extension,such as a tube having a plurality of blowing openings. In accordancewith one embodiment, an extension enters inside of the intermediatecontainer through the second aperture some time after the opening issealed and the extension extends to within about 25.4 mm to 50.8 mm (1.0in.-2.0 in.) of the lowermost portion of the intermediate container.

The raw gas may be comprised of aliphatic hydrocarbons, aromatichydrocarbons, oxygen containing hydrocarbons, nitrogen containinghydrocarbons, etc., in gaseous or liquid state at a room temperature.Benzene, toluene, o-xylene, m-xylene, p-xylene and cyclohexane eachhaving six or more than six carbons are preferable. The raw gases may beused singularly, but a mixture of two or more than two kinds of rawgases can also be used. Moreover, the raw gases maybe used in the stateof dilution with inert gas such as argon and helium.

At some point after the intermediate container has been received by thereceiving mechanism of the carbon-coating apparatus, the container isinserted into a cylinder or other hollow space provided to accommodatethe intermediate container. In the preferred embodiment, thecarbon-coating apparatus includes a plurality of hollow cylinders thatrotate in the same direction as, and in synchronization with, thereceiving mechanism. It is further preferred that the receivingmechanism that retains and seals the opening of the intermediatecontainer also functions to cover the cylinder.

After the supply of the raw gas into the container, energy is impressedupon the intermediate container from a high frequency electric energysource, such as a microwave-producing device. The impression of theelectric power generates plasma, and causes extreme molecular excitationionization and a carbon coating to be formed on the inner surface of thecontainer, intermediate container to form a carbon-coating inner surfaceas shown in FIGS. 1-4.

While the foregoing method illustrates one process for forming a carboncoating in accordance with the present invention, other conventionalmethods can also be used successfully. For instance, the intermediatecontainer could instead be inserted and accommodated within an externalelectrode and have an internal electrode positioned within thecontainer. After the container is evacuated and is charged with raw gassupplied through the internal electrode, electric power is supplied fromthe high frequency electric source to the external electrode. The supplyof electric power generates plasma between the external electrode andthe internal electrode. Because the internal electrode is earthed, andthe external electrode is insulated by the insulating member, a negativeself-bias is generated on the external electrode, so that carbon film isformed uniformly on the inner surface of the container along theexternal electrode.

When the plasma is generated between the external electrode and theinternal electrode, electrons are accumulated on the inner surface ofthe insulated external electrode to electrify negatively the externalelectrode, to generate negative self-bias on the external electrode. Atthe external electrode, a voltage drop occurs because of the accumulatedelectrons. At this time, carbon dioxide as the carbon resource exists inthe plasma, and positively ionized carbon resource gas is selectivelycollided with the inner surface of the intermediate container which isdisposed along the external electrode, and, then, carbons close to eachother are bonded together thereby to form a hard carbon film comprisinga remarkably dense coating on the inner surface 122 of container 100.

The thickness and uniformity of the carbon coating can be varied byadjusting the output of high frequency; the pressure of the raw gas inthe intermediate container; the flow rate for charging the containerwith gas; the period of time during which plasma is generated; theself-bias and kind of raw materials used; and other like variables.However, the thickness of the carbon coating is preferably within arange from 0.05 to 10 μm to obtain the effective suppression of thepermeation and/or absorption of the low molecular organic compound andthe improved gas barrier property, in addition to an excellent adhesionto plastic, a good durability and a good transparency.

The container of the present invention offers significant advantages.The base container is a mono-layer material that can be readilyprocessed by conventional means. Moreover, the recycled base materialcan be readily admixed with other materials and due to the inner carboncoating does not contact the container contents. Moreover, barrierproperties are readily and easily obtained and the container contentsare not impacted by adverse aromas or taste. Further, the container ofthe present invention eliminates the need for a separate barrier lineror a virgin liner. The small amount of inner carbon coating dos notadversely affect recycling, and colored materials can be readily used toprovide a desirably colored container, for example, the outer layer canbe easily colored in a desirable commercial color.

The present container offers the significant advantages of a mono-layercontainer with desirable engineered properties, as barrier resistanceand low cost. Thus, processing is significantly easier than withmulti-layer containers since one is working with a mono-layer materialwithout the necessity for the use of liners and complicated coinjectionprocessing. Further, one can blend the recycled plastic with othermaterials to readily obtain special properties while still retaining theuse of desirably low cost recycled plastic. For example, one couldcustomize the product in order to obtain desirable characteristics whilestill using recycled material and a mono-layer material.

The internal carbon coating is simply and conveniently applied and isquite thin and yet precludes the migration of adverse flavors and tasteinto the contents of the container. It is particularly desirable to usea variety of colors for the recycled plastic as for example an ambercolor for beer. It would be highly desirable to use such a container asin the present invention with a tailored color and for a beer or softdrink or juice product. As a still further alternative, one could blendheat resistant plastic with the recycled plastic to obtain highlydesirable characteristics.

Although certain preferred embodiments of the present invention havebeen described, the invention is not limited to the illustrationsdescribed and shown herein, which are deemed to be merely illustrativeof the best modes of carrying out the invention. A person or ordinaryskill in the art will realize that certain alternatives, modifications,and variations will come within the teachings of this invention and thatsuch alternatives, modifications, and variations are within the spiritand the broad scope of the appended claims.

What is claimed is:
 1. A blow molded container for holding contents having barrier properties and incorporating a recycled plastic content, said container including an upper wall portion having an opening, a sidewall portion positioned beneath the upper wall portion, and a base portion positioned beneath the sidewall portion which supports the container, said container further comprising: a molded outer single layer having an inner surface and an outer surface and formed from at least 50% of recycled plastic content, said outer layer having a thickness of from 6 to 23 mils; an innermost, non-structural amorphous carbon coating formed on the entire inner surface of the outer layer and adhered thereto, wherein said carbon coating has a thickness from about 0.5 to 10 microns and wherein the thickness of the carbon coating controllably varies along the vertical length of the container and is independently controllably varied with respect to the outer layer, wherein said recycled plastic content does not come into contact with the contents of said container, and wherein said container is recycled.
 2. A container according to claim 1, including at least 90% of recycled plastic.
 3. A container according to claim 1, wherein the thickness of the outer layer varies so that the intermediate sidewall portion is thinner than the upper wall portion and the base portion.
 4. A container according to claim 1, including a barrier material added to the outer layer.
 5. A container according to claim 1, wherein the carbon is coated on the inner surface of the blow molded container from at least one gaseous hydrocarbon.
 6. A container according to claim 1, wherein the recycled plastic is polyethylene terephthalate.
 7. A container according to claim 1, wherein the outer layer includes virgin plastic material.
 8. A container according to claim 1, wherein the upper portion of the container includes a support flange.
 9. A container according to claim 1, wherein the base portion includes a plurality of feet.
 10. A container according to claim 1, wherein the outer layer is colored.
 11. A container according to claim 1, including at least 75% of recycled plastic.
 12. A container according to claim 1, wherein said container is filled with contents.
 13. A container according to claim 12, wherein said container is filled with food products.
 14. A container according to claim 12, wherein said container is filled with contents selected from the group consisting of beer, soft drinks and juice.
 15. A container according to claim 12, wherein said carbon coating protects the contents of the container.
 16. A container according to claim 12, wherein said container precludes the migration of adverse flavors and tastes into the container contents.
 17. A container according to claim 12, wherein said container affords protection from oxygen and carbon dioxide permeation.
 18. A container according to claim 1, wherein said container consists solely of said inner and outer layers.
 19. A container according to claim 1, wherein said carbon coating is a hydrogenated amorphous carbon that is doped with nitrogen.
 20. A blow molded container for holding contents having barrier properties and incorporating a recycled plastic content, said container including an upper wall portion having an opening, a sidewall portion positioned beneath the upper wall portion, and a base portion positioned beneath the sidewall portion which supports the container, said container further comprising: a molded outer single layer having an inner surface and an outer surface and including recycled plastic content, said outer layer having a thickness of from 6 to 23 mils; an innermost, non-structural amorphous carbon coating formed on the entire inner surface of the outer layer and adhered thereto, wherein said carbon coating has a thickness from about 0.5 to 10 microns and wherein the thickness of the carbon coating controllably varies along the vertical length of the container and is independently controllably vaired with respect to the outer layer, wherein said recycled plastic content does not come into contact with the contents of said container, and wherein said container is recycled. 